EP3187695A1 - A wrap comprising sheets of graphene for a casing of a rotating member, corresponding turbofan engine and method of asssaembling a turbofan engine - Google Patents

A wrap comprising sheets of graphene for a casing of a rotating member, corresponding turbofan engine and method of asssaembling a turbofan engine Download PDF

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Publication number
EP3187695A1
EP3187695A1 EP16206187.3A EP16206187A EP3187695A1 EP 3187695 A1 EP3187695 A1 EP 3187695A1 EP 16206187 A EP16206187 A EP 16206187A EP 3187695 A1 EP3187695 A1 EP 3187695A1
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EP
European Patent Office
Prior art keywords
casing
wrap
graphene sheets
graphene
sheets
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16206187.3A
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German (de)
French (fr)
Inventor
Antonio GUIJARRO VALENCIA
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General Electric Co
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General Electric Co
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Publication of EP3187695A1 publication Critical patent/EP3187695A1/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/24Casings; Casing parts, e.g. diaphragms, casing fastenings
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/15Nano-sized carbon materials
    • C01B32/182Graphene
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/15Nano-sized carbon materials
    • C01B32/182Graphene
    • C01B32/194After-treatment
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D11/00Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/14Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing
    • F01D11/16Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing by self-adjusting means
    • F01D11/18Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing by self-adjusting means using stator or rotor components with predetermined thermal response, e.g. selective insulation, thermal inertia, differential expansion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D21/00Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
    • F01D21/04Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position
    • F01D21/045Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for responsive to undesired position of rotor relative to stator or to breaking-off of a part of the rotor, e.g. indicating such position special arrangements in stators or in rotors dealing with breaking-off of part of rotor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/08Cooling; Heating; Heat-insulation
    • F01D25/14Casings modified therefor
    • F01D25/145Thermally insulated casings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/24Casings; Casing parts, e.g. diaphragms, casing fastenings
    • F01D25/26Double casings; Measures against temperature strain in casings
    • F01D25/265Vertically split casings; Clamping arrangements therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C3/00Gas-turbine plants characterised by the use of combustion products as the working fluid
    • F02C3/04Gas-turbine plants characterised by the use of combustion products as the working fluid having a turbine driving a compressor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/26Rotors specially for elastic fluids
    • F04D29/32Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/26Rotors specially for elastic fluids
    • F04D29/32Rotors specially for elastic fluids for axial flow pumps
    • F04D29/325Rotors specially for elastic fluids for axial flow pumps for axial flow fans
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/40Casings; Connections of working fluid
    • F04D29/52Casings; Connections of working fluid for axial pumps
    • F04D29/522Casings; Connections of working fluid for axial pumps especially adapted for elastic fluid pumps
    • F04D29/526Details of the casing section radially opposing blade tips
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/58Cooling; Heating; Diminishing heat transfer
    • F04D29/582Cooling; Heating; Diminishing heat transfer specially adapted for elastic fluid pumps
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00Structure or properties of graphene
    • C01B2204/02Single layer graphene
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00Structure or properties of graphene
    • C01B2204/04Specific amount of layers or specific thickness
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00Structure or properties of graphene
    • C01B2204/20Graphene characterized by its properties
    • C01B2204/24Thermal properties
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00Structure or properties of graphene
    • C01B2204/20Graphene characterized by its properties
    • C01B2204/26Mechanical properties
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00Application
    • F05D2220/30Application in turbines
    • F05D2220/36Application in turbines specially adapted for the fan of turbofan engines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00Manufacture
    • F05D2230/20Manufacture essentially without removing material
    • F05D2230/23Manufacture essentially without removing material by permanently joining parts together
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00Components
    • F05D2240/35Combustors or associated equipment
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/20Oxide or non-oxide ceramics
    • F05D2300/22Non-oxide ceramics
    • F05D2300/224Carbon, e.g. graphite
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/50Intrinsic material properties or characteristics
    • F05D2300/501Elasticity
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/50Intrinsic material properties or characteristics
    • F05D2300/502Thermal properties
    • F05D2300/5024Heat conductivity
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/60Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603Composites; e.g. fibre-reinforced
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/70Treatment or modification of materials
    • F05D2300/702Reinforcement
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft

Definitions

  • This invention relates generally to turbofan engines, and more particularly, to methods and apparatus for operating turbofan engines.
  • Turbofan engines typically include high and low pressure compressors, a combustor, and at least one turbine.
  • the compressors compress air which is mixed with fuel and channeled to the combustor.
  • the mixture is then ignited for generating hot combustion gases, and the combustion gases are channeled to the turbine which extracts energy from the combustion gases for powering the compressor, as well as producing useful work to propel an aircraft in flight or to power a load, such as an electrical generator.
  • foreign objects may be ingested into the engines. More specifically, various types of foreign objects may be entrained in the inlet of a turbofan engine, ranging from large birds, such as sea gulls, to hailstones, sand and rain. The foreign objects may impact a blade resulting in a portion of the impacted blade being torn loose from a rotor. Such a condition, known as foreign object damage, may cause the rotor blade to pierce an engine casing resulting in cracks along an exterior surface of the engine casing, and possible injury to nearby personnel. Additionally, the foreign object damage may cause a portion of the engine to bulge or deflect resulting in increased stresses along the entire engine casing.
  • At least some known engines include a metallic casing shell to facilitate increasing a radial and an axial stiffness of the engine, and to facilitate reducing stresses near the engine casing penetration.
  • casing shells are typically fabricated from a metallic material which results in an increased weight of the engine and therefore the airframe.
  • thermal conduction and the resulting localized thermal expansion and contraction of elements of the engine casing induce local thermal stresses that may deform the engine casing, thereby degrading engine performance.
  • local thermal stresses may deform a compressor casing out of round, impacting compressor clearance and further hampering the ability to control compressor clearance.
  • Existing casing reinforcement materials, such as Kevlar are insulating, and further exacerbate the local thermal stresses within the engine casing.
  • the matrix is further configured to receive an adhesive or mechanical fastener.
  • the matrix is further configured to bond to a surface of the casing using the adhesive or mechanical fastener.
  • the wrap is further configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • a method of assembling a turbofan engine with a casing surrounding a rotating member includes providing one or more graphene sheets.
  • the graphene sheets contain graphene and a matrix configured to stabilize the graphene.
  • the method also includes bonding the matrix of the one or more graphene sheets to a surface of the casing using an adhesive or using mechanical fasteners inserted through a plurality of connecting rings formed within the matrix and into the surface of the casing to form a wrap.
  • the wrap includes the one or more graphene sheets and the matrix. The wrap is configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • a turbofan engine in an additional aspect, includes a core engine comprising a rotating member surrounded by a casing and a wrap covering at least a portion of a surface of the casing.
  • the wrap includes one or more graphene sheets, and a matrix configured to stabilize the one or more graphene sheets.
  • the matrix is further configured to receive an adhesive and bond to the surface of the casing using the adhesive.
  • the wrap is further configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • Approximating language may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value.
  • range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
  • the disclosure has general application to a wrap and a method of using the wrap to facilitate heat transfer over a casing of a turbofan engine and to structurally reinforce the casing.
  • various embodiments of the wrap and method of using the wrap are described in terms of this exemplary embodiment, it is to be understood that the wrap and method are suitable for facilitating heat transfer and structurally reinforcing a body as defined herein without limitation.
  • a wrap comprising one or more graphene sheets is bonded to a casing of a turbofan engine, thereby enhancing heat transfer over the casing and providing structural reinforcement to the casing.
  • the graphene within the graphene sheets is an advanced material known for being about 200 times stiffer than steel and for conducting heat 10 times faster than copper, as well as for light weight. Wrapping the casing with graphene enhances the containment characteristics of the casing in the event of an intake of a foreign object into the turbofan engine and/or a blade failure.
  • the graphene casing wrap facilitates uniform heat conduction around the casing allowing for better tip clearance control.
  • the high strength of graphene enables a reduction of the thickness relative to existing designs that make use of materials such as Kevlar, and an associated reduction in weight of the turbofan engine.
  • FIG. 1 is a schematic illustration of a turbo fan engine 10 that includes a fan assembly 12 and a core engine 13 including a high pressure compressor 14, and a combustor 16.
  • Engine 10 also includes a high pressure turbine 18, a low pressure turbine 20, and a booster 22.
  • Fan assembly 12 includes an array of fan blades 24 extending radially outward from a rotor disc 26.
  • Engine 10 has an intake side 28 and an exhaust side 30.
  • Fan assembly 12 and turbine 20 are coupled by a first rotor shaft 31, and compressor 14 and turbine 18 are coupled by a second rotor shaft 32.
  • Airflow (not shown in Figure 1 ) from combustor 16 drives turbines 18 and 20, and turbine 20 drives fan assembly 12 by way of shaft 31.
  • FIG. 2 is a cross-sectional view of a casing 35 from a portion of core engine 13 and an exemplary wrap 50.
  • wrap 50 includes one or more graphene sheets 52, 54 that are bonded to a surface 44 of casing 35.
  • one or more graphene sheets may be bonded to casing 35 in separate locations on casing 35.
  • first graphene sheet 52 is bonded to surface 44 of a first casing element 36 and second graphene sheet 54 is bonded to surface 44 of second casing element 38.
  • any number of graphene sheets may be bonded to casing 35 without limitation.
  • the use of one or more graphene sheets 52, 54 enables a closer fit of wrap 50 over surface 44 of casing 35, and further enables wrap 50 to conform to various projections and/or other irregularities of surface 44.
  • wrap 50 further includes a gap 90 between abutted graphene sheets 52, 54.
  • gap 90 may be included in wrap 50 to enable easy access to certain components of casing 35.
  • gap 90 may be situated over a joint 40 between elements 36, 38 of casing 35 to facilitate maintenance of casing 35.
  • gap 90 may be included in wrap 50 to accommodate deformation of casing 35 due to thermal stresses experienced during operation of turbofan engine 10.
  • gap 90 may be sized to accommodate the expected range of deformation due to thermal stresses.
  • gap 90 may be sized to control heat transfer by defining a discontinuity in thermally conductive graphene sheets 52, 54 of wrap 50.
  • wrap 50 is bonded to at least a portion of surface 44 of casing 35. In some embodiments, wrap 50 is bonded to a region of surface 44 to ameliorate deformation due to thermal stresses.
  • wrap 50 is bonded to surface 44 of casing 35 in segments of high pressure compressor 14. In this example, wrap 50 enables enhanced thermal transfer from casing 35, thereby facilitating control of compressor clearance by reducing thermal expansion and/or contraction during operation of turbofan engine 10.
  • wrap 50 is bonded to surface 44 of casing 35 in segments of fan assembly 12.
  • wrap 50 may be bonded to surface 44 of casing 35 in regions corresponding to a prime containment zone (not illustrated), corresponding to a zone that extends both axially and circumferentially around fan assembly 12 and represents an area wherein a fan blade (not shown) is most likely to be radially flung or ejected from fan assembly 12 in the event of a blade failure.
  • a prime containment zone not illustrated
  • FIG. 3 is an enlargement of first casing element 36 with one or more graphene sheets 52 bonded to surface 44 in an exemplary embodiment.
  • one or more graphene sheets 52 may include at least 10 individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 arranged as layers as illustrated in FIG. 3 .
  • One or more graphene sheets 52 are bonded to surface 44 of first casing element 36 with an adhesive layer 56 between innermost graphene sheet 58 and surface 44 of first casing element 36.
  • wrap 50 includes at least 10 graphene sheets arranged in layers. In various other embodiments, wrap 50 includes at least 20 graphene sheets, at least 30 graphene sheets, at least 40 graphene sheets, at least 50 graphene sheets, at least 60 graphene sheets, at least 70 graphene sheets, at least 80 graphene sheets, at least 90 graphene sheets, or at least 100 graphene sheets, arranged in layers. In another embodiment, wrap 50 includes a plurality of graphene sheets ranging from about 10 to about 100 graphene sheets arranged in layers. In these embodiments, the number of graphene sheets arranged in layers may be selected to enable a desired level of structural reinforcement and/or to enable a desired enhancement in heat conduction for casing 35.
  • wrap 50 may further include one or more additional graphene sheets 92 at a selected region 96 of casing 35 in one embodiment.
  • one or more additional graphene sheets 92 are configured to control heat transfer at selected region 96. Region 96 is selected based on a determination of a hot spot in casing 35.
  • wrap 50 further includes one or more flexible graphene sheets 94 situated over one or more protrusions 42 projecting from surface 44 of casing 35.
  • One or more flexible graphene sheets 94 may be situated over local regions that contain protrusions 42 to accommodate protrusions 42 and enable a close fit and bonding of wrap 50 to casing 35.
  • one or more flexible graphene sheets 94 are situated over protrusion 42 associated with a joint 40 of casing elements 36, 38.
  • FIG. 4 is a top close-up view of individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78.
  • Each individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 comprises a plurality of carbon atoms 84 in a single layer joined by covalent bonds 86 and arranged in a plurality of fused hexagonal rings in a sheet that is one atom thick.
  • Each individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 further includes a matrix 88 configured to stabilize the graphene within graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78.
  • Any suitable matrix material may be used without limitation including, but not limited to a metallic matrix.
  • wrap 50 is bonded to surface 44 of casing 35 using adhesive 56.
  • Any suitable adhesive 56 may be used to bond wrap 50 to surface 44 without limitation.
  • suitable adhesives include high temperature epoxy resins capable of withstanding temperatures of up to about 650° F, representative of ambient temperatures during engine operation.
  • wrap 50 may be bonded to surface 44 at innermost graphene sheet 58.
  • matrix 88 is configured to receive adhesive 56 to facilitate bonding of wrap 50 to surface 44.
  • individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may be bonded to one another using adhesive (not illustrated) between adjacent graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78.
  • adhesive not illustrated
  • the bonding of graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may enhance the thermal conductivity and structural integrity of wrap 50.
  • wrap 50 is bonded to surface 44 of casing 35 using a plurality of mechanical fasteners 97.
  • each mechanical fastener 97 is inserted through a connecting ring 98 formed within matrix 88 of wrap 50.
  • Any suitable fastener 97 may be used to bond wrap 50 to surface 44 including, but not limited to, screws, rivets, staples, and any other suitable mechanical fastener 97 without limitation.
  • Wrap 50 is provided with a plurality of connecting rings 98 formed within matrix 88 to receive plurality of fasteners 97 to enhance the bonding of wrap 50 to surface 44 of casing 35.
  • individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may be bonded to one another using adhesive (not illustrated) between adjacent graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 as described herein previously, and wrap 50 is bonded to surface 44 of casing 35 using plurality of mechanical fasteners 97.
  • both adhesive 56 and plurality of mechanical fasteners 97 are used to bond wrap 50 to surface 44 of casing 35.
  • a turbofan engine 10 may incorporate wrap 50 to enhance heat conduction and structural integrity of casing 35.
  • wrap 50 covers surface 44 of casing 35 surrounding rotating member (not illustrated) of core engine 13.
  • Wrap 50 comprises at least one graphene sheet 52, 54 and matrix 88 bonded to surface 44 of casing 35 using adhesive 56, as described herein previously.
  • wrap, methods of using a wrap to facilitate the heat conduction and structural integrity of a casing of a turbofan engine are described above in detail.
  • the wrap, and methods of using such wrap are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.
  • the methods may also be used in combination with other systems requiring selective heat transfer and/or structural reinforcement, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other machinery applications that are currently configured to receive and accept heat transfer and structural reinforcement elements.
  • Example methods and apparatus for facilitating heat transfer and enhancing structural integrity of a casing of a turbofan engine are described above in detail.
  • the apparatus illustrated is not limited to the specific embodiments described herein, but rather, components of each may be utilized independently and separately from other components described herein. Each system component can also be used in combination with other system components.

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Abstract

A wrap (50) configured to cover a surface (44) of a casing (35) surrounding a rotating member includes one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) and a matrix (88) configured to stabilize the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78). The matrix (88) further configured to receive an adhesive (56) or mechanical fastener (97) and to bond to a surface (44) of the casing (35) using the adhesive (56) or mechanical fastener (97). The wrap (50) is further configured to facilitate heat transfer over the casing (35), to structurally reinforce the casing (35), and to enhance containment resilience. Corresponding turbofan engine and method of assembling a turbofan engine are also provided.

Description

    BACKGROUND
  • This invention relates generally to turbofan engines, and more particularly, to methods and apparatus for operating turbofan engines.
  • Turbofan engines typically include high and low pressure compressors, a combustor, and at least one turbine. The compressors compress air which is mixed with fuel and channeled to the combustor. The mixture is then ignited for generating hot combustion gases, and the combustion gases are channeled to the turbine which extracts energy from the combustion gases for powering the compressor, as well as producing useful work to propel an aircraft in flight or to power a load, such as an electrical generator.
  • When turbofan engines operate in various conditions, foreign objects may be ingested into the engines. More specifically, various types of foreign objects may be entrained in the inlet of a turbofan engine, ranging from large birds, such as sea gulls, to hailstones, sand and rain. The foreign objects may impact a blade resulting in a portion of the impacted blade being torn loose from a rotor. Such a condition, known as foreign object damage, may cause the rotor blade to pierce an engine casing resulting in cracks along an exterior surface of the engine casing, and possible injury to nearby personnel. Additionally, the foreign object damage may cause a portion of the engine to bulge or deflect resulting in increased stresses along the entire engine casing.
  • To facilitate preventing the increased engine stresses and the possible injury to personnel, at least some known engines include a metallic casing shell to facilitate increasing a radial and an axial stiffness of the engine, and to facilitate reducing stresses near the engine casing penetration. However, casing shells are typically fabricated from a metallic material which results in an increased weight of the engine and therefore the airframe.
  • In addition, thermal conduction and the resulting localized thermal expansion and contraction of elements of the engine casing induce local thermal stresses that may deform the engine casing, thereby degrading engine performance. For example, local thermal stresses may deform a compressor casing out of round, impacting compressor clearance and further hampering the ability to control compressor clearance. Existing casing reinforcement materials, such as Kevlar, are insulating, and further exacerbate the local thermal stresses within the engine casing.
  • BRIEF DESCRIPTION
  • In one aspect, a wrap configured to cover a surface of a casing surrounding a rotating member includes one or more graphene sheets and a matrix configured to stabilize said one or more graphene sheets. The matrix is further configured to receive an adhesive or mechanical fastener. The matrix is further configured to bond to a surface of the casing using the adhesive or mechanical fastener. The wrap is further configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • In another aspect, a method of assembling a turbofan engine with a casing surrounding a rotating member includes providing one or more graphene sheets. The graphene sheets contain graphene and a matrix configured to stabilize the graphene. The method also includes bonding the matrix of the one or more graphene sheets to a surface of the casing using an adhesive or using mechanical fasteners inserted through a plurality of connecting rings formed within the matrix and into the surface of the casing to form a wrap. The wrap includes the one or more graphene sheets and the matrix. The wrap is configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • In an additional aspect, a turbofan engine includes a core engine comprising a rotating member surrounded by a casing and a wrap covering at least a portion of a surface of the casing. The wrap includes one or more graphene sheets, and a matrix configured to stabilize the one or more graphene sheets. The matrix is further configured to receive an adhesive and bond to the surface of the casing using the adhesive. The wrap is further configured to facilitate heat transfer over the casing, to structurally reinforce the casing, and to enhance containment resilience.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
    • FIGS. 1-4 show example embodiments of the wrap and method described herein.
    • FIG. 1 is schematic illustration of a turbofan engine.
    • FIG. 2 is a cross-sectional view of an engine casing with an attached wrap;
    • FIG. 3 is a close-up view of the wrap of FIG. 2 bonded to the surface of the engine casing; and
    • FIG. 4 is top view of a graphene sheet.
  • Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.
  • Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
  • DETAILED DESCRIPTION
  • In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
  • The singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise.
  • "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
  • Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about", "approximately", and "substantially", are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
  • The following detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to a wrap and a method of using the wrap to facilitate heat transfer over a casing of a turbofan engine and to structurally reinforce the casing. Although various embodiments of the wrap and method of using the wrap are described in terms of this exemplary embodiment, it is to be understood that the wrap and method are suitable for facilitating heat transfer and structurally reinforcing a body as defined herein without limitation.
  • In various embodiments, a wrap comprising one or more graphene sheets is bonded to a casing of a turbofan engine, thereby enhancing heat transfer over the casing and providing structural reinforcement to the casing. The graphene within the graphene sheets is an advanced material known for being about 200 times stiffer than steel and for conducting heat 10 times faster than copper, as well as for light weight. Wrapping the casing with graphene enhances the containment characteristics of the casing in the event of an intake of a foreign object into the turbofan engine and/or a blade failure. In addition, the graphene casing wrap facilitates uniform heat conduction around the casing allowing for better tip clearance control. The high strength of graphene enables a reduction of the thickness relative to existing designs that make use of materials such as Kevlar, and an associated reduction in weight of the turbofan engine.
  • FIG. 1 is a schematic illustration of a turbo fan engine 10 that includes a fan assembly 12 and a core engine 13 including a high pressure compressor 14, and a combustor 16. Engine 10 also includes a high pressure turbine 18, a low pressure turbine 20, and a booster 22. Fan assembly 12 includes an array of fan blades 24 extending radially outward from a rotor disc 26. Engine 10 has an intake side 28 and an exhaust side 30. Fan assembly 12 and turbine 20 are coupled by a first rotor shaft 31, and compressor 14 and turbine 18 are coupled by a second rotor shaft 32.
  • During operation, air flows through fan assembly 12, along a central axis 34, and compressed air is supplied to high pressure compressor 14. The highly compressed air is delivered to combustor 16. Airflow (not shown in Figure 1) from combustor 16 drives turbines 18 and 20, and turbine 20 drives fan assembly 12 by way of shaft 31.
  • FIG. 2 is a cross-sectional view of a casing 35 from a portion of core engine 13 and an exemplary wrap 50. In the exemplary embodiment, wrap 50 includes one or more graphene sheets 52, 54 that are bonded to a surface 44 of casing 35. In various embodiments, one or more graphene sheets may be bonded to casing 35 in separate locations on casing 35. In the exemplary embodiment, first graphene sheet 52 is bonded to surface 44 of a first casing element 36 and second graphene sheet 54 is bonded to surface 44 of second casing element 38. In various aspects, any number of graphene sheets may be bonded to casing 35 without limitation. The use of one or more graphene sheets 52, 54 enables a closer fit of wrap 50 over surface 44 of casing 35, and further enables wrap 50 to conform to various projections and/or other irregularities of surface 44.
  • In this exemplary embodiment, wrap 50 further includes a gap 90 between abutted graphene sheets 52, 54. In various aspects, gap 90 may be included in wrap 50 to enable easy access to certain components of casing 35. By way of non-limiting example, gap 90 may be situated over a joint 40 between elements 36, 38 of casing 35 to facilitate maintenance of casing 35. In various other embodiments, gap 90 may be included in wrap 50 to accommodate deformation of casing 35 due to thermal stresses experienced during operation of turbofan engine 10. In these embodiments, gap 90 may be sized to accommodate the expected range of deformation due to thermal stresses. In other embodiments, gap 90 may be sized to control heat transfer by defining a discontinuity in thermally conductive graphene sheets 52, 54 of wrap 50.
  • In various embodiments, wrap 50 is bonded to at least a portion of surface 44 of casing 35. In some embodiments, wrap 50 is bonded to a region of surface 44 to ameliorate deformation due to thermal stresses. By way of non-limiting example, wrap 50 is bonded to surface 44 of casing 35 in segments of high pressure compressor 14. In this example, wrap 50 enables enhanced thermal transfer from casing 35, thereby facilitating control of compressor clearance by reducing thermal expansion and/or contraction during operation of turbofan engine 10. By way of another non-limiting example, wrap 50 is bonded to surface 44 of casing 35 in segments of fan assembly 12. In this example, wrap 50 may be bonded to surface 44 of casing 35 in regions corresponding to a prime containment zone (not illustrated), corresponding to a zone that extends both axially and circumferentially around fan assembly 12 and represents an area wherein a fan blade (not shown) is most likely to be radially flung or ejected from fan assembly 12 in the event of a blade failure.
  • FIG. 3 is an enlargement of first casing element 36 with one or more graphene sheets 52 bonded to surface 44 in an exemplary embodiment. In this exemplary embodiment, one or more graphene sheets 52 may include at least 10 individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 arranged as layers as illustrated in FIG. 3. One or more graphene sheets 52 are bonded to surface 44 of first casing element 36 with an adhesive layer 56 between innermost graphene sheet 58 and surface 44 of first casing element 36.
  • In various embodiments, wrap 50 includes at least 10 graphene sheets arranged in layers. In various other embodiments, wrap 50 includes at least 20 graphene sheets, at least 30 graphene sheets, at least 40 graphene sheets, at least 50 graphene sheets, at least 60 graphene sheets, at least 70 graphene sheets, at least 80 graphene sheets, at least 90 graphene sheets, or at least 100 graphene sheets, arranged in layers. In another embodiment, wrap 50 includes a plurality of graphene sheets ranging from about 10 to about 100 graphene sheets arranged in layers. In these embodiments, the number of graphene sheets arranged in layers may be selected to enable a desired level of structural reinforcement and/or to enable a desired enhancement in heat conduction for casing 35.
  • Referring again to FIG. 2, wrap 50 may further include one or more additional graphene sheets 92 at a selected region 96 of casing 35 in one embodiment. In this embodiment, one or more additional graphene sheets 92 are configured to control heat transfer at selected region 96. Region 96 is selected based on a determination of a hot spot in casing 35.
  • In another embodiment, wrap 50 further includes one or more flexible graphene sheets 94 situated over one or more protrusions 42 projecting from surface 44 of casing 35. One or more flexible graphene sheets 94 may be situated over local regions that contain protrusions 42 to accommodate protrusions 42 and enable a close fit and bonding of wrap 50 to casing 35. By way of non-limiting example, one or more flexible graphene sheets 94 are situated over protrusion 42 associated with a joint 40 of casing elements 36, 38.
  • FIG. 4 is a top close-up view of individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78. Each individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 comprises a plurality of carbon atoms 84 in a single layer joined by covalent bonds 86 and arranged in a plurality of fused hexagonal rings in a sheet that is one atom thick. Each individual graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 further includes a matrix 88 configured to stabilize the graphene within graphene sheet 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78. Any suitable matrix material may be used without limitation including, but not limited to a metallic matrix.
  • In one embodiment, wrap 50 is bonded to surface 44 of casing 35 using adhesive 56. Any suitable adhesive 56 may be used to bond wrap 50 to surface 44 without limitation. Non-limiting examples of suitable adhesives include high temperature epoxy resins capable of withstanding temperatures of up to about 650° F, representative of ambient temperatures during engine operation. In one embodiment, wrap 50 may be bonded to surface 44 at innermost graphene sheet 58. In another embodiment, matrix 88 is configured to receive adhesive 56 to facilitate bonding of wrap 50 to surface 44. In an additional embodiment, individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may be bonded to one another using adhesive (not illustrated) between adjacent graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78. In this embodiment, the bonding of graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may enhance the thermal conductivity and structural integrity of wrap 50.
  • In one embodiment, wrap 50 is bonded to surface 44 of casing 35 using a plurality of mechanical fasteners 97. In this embodiment, each mechanical fastener 97 is inserted through a connecting ring 98 formed within matrix 88 of wrap 50. Any suitable fastener 97 may be used to bond wrap 50 to surface 44 including, but not limited to, screws, rivets, staples, and any other suitable mechanical fastener 97 without limitation. Wrap 50 is provided with a plurality of connecting rings 98 formed within matrix 88 to receive plurality of fasteners 97 to enhance the bonding of wrap 50 to surface 44 of casing 35. In another embodiment, individual graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 may be bonded to one another using adhesive (not illustrated) between adjacent graphene sheets 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78 as described herein previously, and wrap 50 is bonded to surface 44 of casing 35 using plurality of mechanical fasteners 97. In another embodiment, both adhesive 56 and plurality of mechanical fasteners 97 are used to bond wrap 50 to surface 44 of casing 35.
  • In one embodiment, a turbofan engine 10 may incorporate wrap 50 to enhance heat conduction and structural integrity of casing 35. In this embodiment, wrap 50 covers surface 44 of casing 35 surrounding rotating member (not illustrated) of core engine 13. Wrap 50 comprises at least one graphene sheet 52, 54 and matrix 88 bonded to surface 44 of casing 35 using adhesive 56, as described herein previously.
  • Exemplary embodiments of wrap, methods of using a wrap to facilitate the heat conduction and structural integrity of a casing of a turbofan engine are described above in detail. The wrap, and methods of using such wrap are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.
  • For example, the methods may also be used in combination with other systems requiring selective heat transfer and/or structural reinforcement, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other machinery applications that are currently configured to receive and accept heat transfer and structural reinforcement elements.
  • Example methods and apparatus for facilitating heat transfer and enhancing structural integrity of a casing of a turbofan engine are described above in detail. The apparatus illustrated is not limited to the specific embodiments described herein, but rather, components of each may be utilized independently and separately from other components described herein. Each system component can also be used in combination with other system components.
  • This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
  • Various aspects and embodiments of the present invention are defined by the following numbered clauses:
    1. 1. A wrap for a casing surrounding a rotating member, said wrap comprising:
      • one or more graphene sheets; and
      • a matrix configured receive an adhesive or mechanical fastener, stabilize said one or more graphene sheets, and bond to a surface of the casing using said adhesive or mechanical fastener; and
      said wrap further configured to cover at least a portion of a surface of the casing, facilitate heat transfer over the casing, structurally reinforce the casing, and enhance containment resilience.
    2. 2. The wrap of Clause [0001] 1, wherein said one or more graphene sheets comprise bonded carbon atoms in sheet form approximately one atom thick.
    3. 3. The wrap of any preceding Clause, wherein said one or more graphene sheets comprise at least 10 graphene sheets.
    4. 4. The wrap of any preceding Clause, wherein said one or more graphene sheets comprise from about 10 graphene sheets to about 100 graphene sheets.
    5. 5. The wrap of any preceding Clause, wherein said wrap further comprises a gap between abutted sheets, said gap sized to accommodate a deformation of the casing.
    6. 6. The wrap of any preceding Clause, wherein said wrap further comprises one or more additional graphene sheets configured to control heat transfer at a selected region of the casing, said one or more additional graphene sheets situated at the region, and the region selected based on a determination of a hot spot in the casing.
    7. 7. The wrap of any preceding Clause, wherein said wrap further comprises one or more flexible graphene sheets situated over one or more protrusions projecting from the casing.
    8. 8. A method of assembling a turbofan engine comprising a casing surrounding a rotating member, the method comprising:
      • providing one or more graphene sheets comprising graphene and a matrix configured to stabilize the graphene; and
      • bonding the matrix of the one or more graphene sheets to a surface of the casing using an adhesive or using mechanical fasteners inserted through a plurality of connecting rings formed within the matrix and into the surface of the casing to form a wrap;
      the wrap comprising the one or more graphene sheets and the matrix; and
      the wrap configured to facilitate heat transfer over the casing, to structurally reinforce the casing, to enhance containment resilience, and to enhance containment resilience.
    9. 9. The method of any preceding Clause, wherein the one or more graphene sheets comprise bonded carbon atoms in sheet form approximately one atom thick.
    10. 10. The method of any preceding Clause, wherein the one or more graphene sheets comprises at least 10 graphene sheets.
    11. 11. The method of any preceding Clause, wherein the one or more graphene sheets comprises from about 10 graphene sheets to about 100 graphene sheets.
    12. 12. The method of any preceding Clause, further comprising forming a gap between abutted sheets of the one or more graphene sheets, the gap sized to accommodate a deformation of the casing.
    13. 13. The method of any preceding Clause, further comprising bonding one or more additional graphene sheets configured to control heat transfer at a region of the casing, the region selected based on a determination of a hot spot in the casing.
    14. 14. The method of any preceding Clause, further comprising bonding one or more flexible graphene sheets over one or more protrusions projecting from the casing.
    15. 15. A turbofan engine comprising:
      • a core engine comprising a rotating member surrounded by a casing; and
      • a wrap covering at least a portion of a surface of the casing, said wrap comprising:
        • one or more graphene sheets; and
        • a matrix configured to stabilize said one or more graphene sheets, said matrix further configured to receive an adhesive and bond to the surface of the casing using said adhesive, wherein said wrap is further configured to facilitate heat transfer over the casing and to structurally reinforce the casing.
    16. 16. The turbofan engine of any preceding Clause, wherein said one or more graphene sheets comprise bonded carbon atoms in sheet form approximately one atom thick.
    17. 17. The turbofan engine of any preceding Clause, wherein said one or more graphene sheets comprise at least 10 graphene sheets.
    18. 18. The turbofan engine of any preceding Clause, wherein said wrap further comprises a gap between abutted sheets, said gap sized to accommodate a deformation of the casing.
    19. 19. The turbofan engine of any preceding Clause, wherein said wrap further comprises one or more additional graphene sheets configured to control heat transfer at a region of the casing, said one or more additional graphene sheets situated at the region, and the region selected based on a determination of a hot spot in the casing.
    20. 20. The turbofan engine of any preceding Clause, wherein said wrap further comprises one or more flexible graphene sheets situated over one or more protrusions projecting from the casing.

Claims (15)

  1. A wrap (50) for a casing (35) surrounding a rotating member, said wrap (50) comprising:
    one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78); and
    a matrix (88) configured receive an adhesive (56) or mechanical fastener (97), stabilize said one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78), and bond to a surface (44) of the casing (35) using said adhesive (56) or mechanical fastener (97); and
    said wrap (50) further configured to cover at least a portion of a surface (44) of the casing (35), facilitate heat transfer over the casing (35), and structurally reinforce the casing (35), and enhance containment resilience.
  2. The wrap (50) of Claim 1, wherein said one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprise bonded carbon atoms (84) in sheet form approximately one atom thick.
  3. The wrap (50) of either of Claim 1 or 2, wherein said one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprise at least 10 graphene sheets.
  4. The wrap (50) of any preceding Claim, wherein said one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprise from about 10 graphene sheets to about 100 graphene sheets.
  5. The wrap (50) of any preceding Claim, wherein said wrap (50) further comprises a gap (90) between abutted sheets (52,54), said gap (90) sized to accommodate a deformation of the casing (35).
  6. The wrap (50) of any preceding Claim, wherein said wrap (50) further comprises one or more additional graphene sheets (92) configured to control heat transfer at a selected region (96) of the casing (35), said one or more additional graphene sheets (92) situated at the region (96), and the region (96) selected based on a determination of a hot spot in the casing (35).
  7. The wrap (50) of any preceding Claim, wherein said wrap (50) further comprises one or more flexible graphene sheets (94) situated over one or more protrusions (42) projecting from the casing (35).
  8. A method of assembling a turbofan engine (10) comprising a casing (35) surrounding a rotating member, the method comprising:
    providing one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprising graphene and a matrix (88) configured to stabilize the graphene; and
    bonding the matrix (88) of the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) to a surface (44) of the casing (35) using an adhesive (56) or using mechanical fasteners (97) inserted through a plurality of connecting rings (98) formed within the matrix (88) and into the surface (44) of the casing (35) to form a wrap (50);
    the wrap (50) comprising the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) and the matrix (88); and
    the wrap (50) configured to facilitate heat transfer over the casing (35), to structurally reinforce the casing (35), and to enhance containment resilience.
  9. The method of Claim 8, wherein the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprise bonded carbon atoms (84) in sheet form approximately one atom thick.
  10. The method of either of Claim 8 or 9, wherein the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprises at least 10 graphene sheets.
  11. The method of any of Claims 8 to 10, wherein the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) comprises from about 10 graphene sheets to about 100 graphene sheets.
  12. The method of any of Claims 8 to 11, further comprising forming a gap (90) between abutted sheets (52,54) of the one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78), the gap (90) sized to accommodate a deformation of the casing (35).
  13. The method of any of Claims 8 to 12, further comprising bonding one or more additional graphene sheets (92) configured to control heat transfer at a region (96) of the casing (35), the region (96) selected based on a determination of a hot spot in the casing (35).
  14. The method of any of Claims 8 to 13, further comprising bonding one or more flexible graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78) over one or more protrusions (42) projecting from the casing (35).
  15. A turbofan engine (10) comprising:
    a core engine (13) comprising a rotating member surrounded by a casing (35); and
    a wrap (50) covering at least a portion of a surface (44) of the casing (35), said wrap (50) comprising:
    one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78); and
    a matrix (88) configured to stabilize said one or more graphene sheets (52,54;58,60,62,64,66,68,70,72,74,76,78), said matrix (88) further configured to receive an adhesive (56) and bond to the surface (44) of the casing (35) using said adhesive (56), wherein said wrap (50) is further configured to facilitate heat transfer over the casing (35), to structurally reinforce the casing (35), and to enhance containment resilience.
EP16206187.3A 2015-12-30 2016-12-22 A wrap comprising sheets of graphene for a casing of a rotating member, corresponding turbofan engine and method of asssaembling a turbofan engine Withdrawn EP3187695A1 (en)

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JP2017129132A (en) 2017-07-27
US20170191498A1 (en) 2017-07-06
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BR102016030886A2 (en) 2017-07-04
CN107035440A (en) 2017-08-11

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